Hi
based on your answer and my understanding of what the real issue is, your first post is ----um ---wrong
You can boot a bootable sd card in your netbook
Your real question is remastering one of the solydk variants but
http://solydxk.com/products/solydk/ is around 1.5G while the xfce edition is around 1.1G according to their website.
but they have a forum
http://forums.solydxk.com/
I suggest you post there about either how to use their iso on an SD card with persistence
---meaning accessing a separate hard drive (internal for you) for your preferencecs
------or insert an usb stick and same deal
OR
remastering completely.
I am also assuming "my personal config" means not just config files but extra packages.
The trouble is KDE is already huge----some might call it bloatware but their alternative is only 400 megs smaller.
good luck
2) if size does matter and you want to put something onto a 2G stick and all your software then you are looking for recommendations for "minimal" distros
but I also suggest now we know you have linux, the iso is to be isohybrid so you can easily image it onto a stick
I am suggesting remastersys is not that easy to trouble shoot for others. Much easy if you take an existing distro and add packages from their repo OR
compile packages using their instructions.
3) the smallest distro with already web browser etc is slitaz
http://distrowatch.com/table.php?distribution=slitaz but does not seem to have frequent updates so next is
tinycore may be better, you can put coreplus on the sd card then grab more stuff off their repo
http://www.tinycorelinux.net/downloads.html